Gusseted pouch

ABSTRACT

A pouch is defined by first and second panels of a flexible laminate. The first and second panels each have an outside first face, an inside first face and a barrier layer disposed between the outside first face and the inside first face. The pouch has first and second gusset portions each having an inside face, a gusset outside face and a barrier layer disposed between the inside face and the outside face. A bottom portion of the inside face of the first panel is bonded to a bottom portion of the inside face of the first gusset. A bottom portion of the inside face of the second panel is bonded to a bottom portion of the inside face of the second gusset. A top portion of the inside face of the first panel is bonded to a top portion of the inside face of the second panel.

FIELD OF THE INVENTION

The invention relates to pouches formed of flexible materials. More specifically, the present invention relates to a gusseted pouch adapted to resist cracking due to flexing.

BACKGROUND

Laminates used for flexible packaging applications, such as gusseted pouches, often contain a barrier layer designed to prevent or control the flow of oxygen and moisture therethrough. Various barrier materials are used for this purpose. When the laminate is formed into a pouch, the barrier material may be compromised cracks or pinholes due to flexing or bending of the laminate. A common area for the compromise is the gusset. It would be beneficial to provide a pouch, constructed of a laminate having a barrier material therein, that has a gusseted insert adapted to resist flex-cracking or pinholes.

SUMMARY OF THE INVENTION

A pouch is defined by a first and second panel of a flexible laminate. The panels each have an outside face, an inside face and a barrier layer disposed between the outside and inside faces. The edge portions of the inside faces of the two panels are bonded to one another to form the pouch reservoir. The pouch is further defined by first and second gusset portions each having an inside face, an outside face and a barrier layer disposed between the inside and outside faces. A portion of the inside face of the first panel is bonded to a portion of the inside face of the first gusset. A portion of the inside face of the second panel is bonded to a portion of the inside face of the second gusset. The outside faces of the gusset portions are also bonded together to complete the gusset panel.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, that this invention is not limited to the precise arrangements and instrumentalities shown.

FIG. 1 is a side sectional view of a pouch according to an embodiment of the present invention.

FIG. 2 is a perspective view of the pouch of FIG. 1.

FIG. 3 is a cross sectional view of a first panel of the pouch of FIG. 1.

FIG. 4 is a cross sectional view of a gusset panel of the pouch of FIG. 1.

FIG. 5 is a cross sectional view of an alternative embodiment of the panel of FIG. 4.

FIG. 6 is a perspective view of the first panel and a gusset panel of the pouch of FIG. 2

FIG. 7 is a side sectional view of an alternative embodiment of a pouch of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

It will be appreciated that the following description is intended to refer to specific embodiments of the invention selected for illustration in the drawings and is not intended to define or limit the invention, other than in the appended claim.

In the drawings, in which like reference numerals indicate like elements, there is shown one or more embodiments of gusseted pouch which is generally referred to by the numeral 10. The pouch 10 is generally made from a laminate material, as will be described in further detail below.

As illustrated in FIGS. 1, 2, 6 and 7, the pouch 10 is constructed with a first outer panel 20, a second outer panel 30, a first gusset panel 40 and a second gusset panel 50. The panels 20, 30, 40 and 50 are preferably sealed together to form a reservoir 12 therebetween. An outer face 24 of the first panel 20 may be printed on or labeled as desired. The outer face 34 of the second panel 30 may also be printed on or labeled as desired. The first and second panels 20, 30 are preferably made from a laminate material having multiple layers.

As illustrated in FIG. 3, a first layer 102 of the laminate makes up an inner face 22 and 32 of the panels 20 and 30, respectively, and is preferably a sealing layer. The sealing layer may be polypropylene, polyethylene, or some other suitable material that facilitates sealing, by heat or otherwise, to another layer or panel. It is preferable that the sealing layer 22 of the first panel 20 be sealable to the sealing layer 32 of the second panel 30 in forming the pouch 10. A second layer 104 is preferably a webbing material, such as nylon, polyester or polypropylene. The second layer 104 preferably provides strength to the panels 20, 30. The second layer 104 is preferably coated with a barrier material 106 that provides resistance against oxygen permeability. The barrier layer is typically a metal foil and may be made from aluminum oxide, silicone oxide or other similar material. Exemplary second layer and barrier combinations may be aluminum oxide coated polyester, silicone oxide coated polyester, metallized polyester, metallized oriented polypropylene or polyvinyl-dichloride coated polyester or some other suitable combination. A third layer 108 defines the outer face 24, 34 of the respective first and second panels 20, 30. The third layer may be printable as desired.

The first and second gusset panels 40, 50 preferably have an identical three layer construction. As illustrated in FIG. 4, a first gusset layer 202 is a sealing layer and may be constructed of polyethylene, polypropylene or some other desirable material. The first gusset layer 202 makes up an outer face 42, 52 of the first and second gusset panels 40, 50. Regardless of the material used for construction, it is preferable that the material first gusset layer 202 be sealable to other surfaces made of the same material. A second gusset layer 204 is preferably a strength layer and may be made of nylon or a polyester webbing material. The second gusset layer 204 is preferably coated with a barrier material 206, which may be aluminum oxide, silicone oxide or similar material. The barrier material 206 preferably resists the permeation of oxygen through the gusset panels 40, 50. A third gusset layer 208 is a sealing layer, similar to the first gusset layer 202. The third gusset layer 208 may be made from polypropylene, polyethylene or other sealing material. The third gusset layer 208 makes up an inner face 44, 54 of the first and second gusset panels. It is preferable that the third gusset layer 208 be sealable to the first layer 102 of the first and second panels 20, 30.

Illustrated in FIG. 5 is an alternative laminate combination for the gusset panels 40, 50. In this laminate, a fourth layer 310 is disposed between second layer 204 and third gusset layers 208. The fourth layer 310 is preferably a strength layer, and is generally the same material, nylon or a polyester webbing, used for the third layer 208. The fourth layer 310 may also be coated with a barrier material 312 in a fashion similar to the coating 206 of the second layer 204. The fourth layer 310 is intended to increase the strength and permeability resistance of the gusset panels 40, 50. A first layer 202 is preferably of the same construction as the first layer 202 of the gusset panel of FIG. 4.

The panels 20, 30, 40 and 50 are preferably heat sealed together, although other forms of attachment may be utilized. With reference to FIGS. 1 and 6, a top edge portion 42 a of the outer face 42 of the first gusset panel 40 is sealed to a top edge portion 52 a of the outer face 52 of the second gusset panel 50. A gusset seal 14 is formed between the gusset panels 40, 50. In this arrangement, the outer faces 42, 52 of the gusset panels 40, 50 contact each other. If the top portions 42 a, 52 a are sealed to each other prior to insertion of the gusset panels 40, 50 into the pouch 10, a flat seal bar may be used. Alternatively, the seal may be made ultrasonically or using another convenient method. During the sealing of the pouch, a flag or other barrier may be needed to prevent the gusset panels 40, 50 from sealing to each other when the first and second panels 20, 30 are sealed to the gusset panels 40, 50. It is also preferable that the thickness “T” of seal be about 0.375 inches.

When sealed together, the gusset panels 40, 50 make up a gusset portion 48. The gusset panels 40, 50 may be sealed together prior to the construction of the pouch 10. Alternatively, the gusset panels 40, 50 may be sealed to each other during the process that seals the gusset panels 40, 50 to the first and second panels 20, 30 and the first and second panels to each other.

An upper seam 16 is shown in FIG. 1 where an upper portion 22 a of the inside face 22 of the first panel 20 is preferably heat sealed to an upper portion 32 a of the inside face 32 of the second panel 30. The upper seam 16 defines the top of the cavity or reservoir 12 formed by the pouch. As shown in FIG. 2, the side portions 22 b of the inside face 22 of the first panel 20 are sealed to the side portions 32 b of the inside face 32 of the second panel. A lower side portion 22 c of the inside faces 22, 32 of the first and second panels 20, 30 may be sealed to side portions 44 b of inner faces of the gusset panels 40, 50. It is preferable that side portions 42 b of the outer faces 42, 52 of the gusset panels be at least partially sealed to each other. Those skilled in the art will recognize that the side portions 42 b may not be sealed to each other or may be sealed along their entire length without departing from the scope of the present invention.

In FIG. 7, an alternative embodiment of the pouch 10 is shown, having a zipper 70 or other reclosable sealing structure attached to the first and second gusset panels 40, 50. The zipper may be sealed into place during fabrication of the gusset portion 48. The zipper 70 is preferably made from first and second portion 72, 74. The first portion 72 is attached to the outer face 42 of the first gusset panel 40. The first zipper portion 72 extends across the entirety of the gusset panel, between the seals located at the opposing side portions 42 b. The second zipper portion 74 is attached to the second gusset portion. The first zipper portion 72 may be a female zipper portion and the second zipper portion 74 male, or some other desirable arrangement. The zipper 70 provides a supplemental and reclosable seal between the first and second gusset panels 40, 50. In this embodiment, it may be desirable to make the gusset seal 14 a push-through seal, or include some other mechanism, to facilitate the opening of the pouch through gusset panels 40, 50. When the user no longer wishes to access the reservoir 14, the zipper portions 72, 74 are engaged, thereby sealing the pouch.

The present invention provides a pouch that is easily flattenable. The panels of the pouch are preferably arranged to minimize the need for, or chance of, folding or creasing, thereby reducing the opportunity for cracking or the development of holes in the barrier layer of the laminate material. There is significantly less of a chance for flex-cracking (or pinholes) that may weaken the integrity of the panels.

A variety of modifications to the embodiments described will be apparent to those skilled in the art from the disclosure provided herein. Thus, the invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. 

1. A pouch comprising: a first panel having an outside first face, an inside first face and a barrier layer disposed between the outside first face and the inside first face; a second panel having an outside second face, an inside second face and a barrier layer disposed between the outside second face and the inside second face; a portion of the periphery of the inside faces of the first and second panels bounded together to define a pouch cavity; a first gusset portion having a first gusset inside face, a first gusset outside face and a barrier layer disposed between the first gusset inside face and the first gusset outside face; and a second gusset portion having a second gusset inside face, a second gusset outside face and a barrier layer disposed between the second gusset inside face and the second gusset outside face; a bottom portion of the inside first face is bonded to a bottom portion of the first gusset inside face, a bottom portion of the inside second face is bonded to a bottom portion of the second gusset inside face, and a top portion of the inside first face is bonded to a top portion of the inside second face, the first and second panels and the first and second gusset portions being bounded together with the first and second panels to form the pouch cavity.
 2. The pouch of claim 1, wherein a sealant layer disposed on each of the inside and outside faces of each of the first and second gusset portions.
 3. The pouch of claim 2, wherein the first and second gusset portions further comprising a strength layer.
 4. The pouch of claim 1, wherein each of the inside first face and the inside second face are coated with a sealant layer.
 5. The pouch of claim 4, wherein the sealant layer is polypropylene.
 6. The pouch of claim 4, wherein the sealant layer is polyethylene.
 7. The pouch of claim 1, wherein the barrier layer is aluminum oxide.
 8. The pouch of claim 1, wherein the barrier layer is silicone oxide.
 9. A collapsible container comprising: a first panel having a sealing side and a non-sealing side; a second panel having a sealing side and a non-sealing side; and third and fourth panels, each having two sealing sides and a barrier layer disposed between the two sealing sides, at least a portion of the sealing side of the first panel is bonded to at least a portion of the sealing side of the second panel and at least a portion of a first sealing side of the third panel, at least a portion of a second sealing side of the third panel is bonded to a portion of a first sealing side of the fourth panel; and at least a portion of the sealing side of the fourth panel is bonded to at least a portion of the sealing side of the first panel and at least a portion of a second sealing side of the fourth panel.
 10. The container of claim 9, each of the first and second panels further comprising a barrier layer.
 11. The container of claim 9, each of the third and fourth panels further comprising a strength layer between the first sealing side and the second sealing side. 